Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
  • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
  • C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
  • C08L51/04—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to rubbers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
  • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
  • C08L67/025—Polyesters derived from dicarboxylic acids and dihydroxy compounds containing polyether sequences
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates

Definitions

• the present invention relates to a thermoplastic resin composition excellent in impact resistance and molded appearance, containing as constituent components a polycarbonate resin, saturated polyester resin and/or polyester-based elastomer, butadiene-based graft copolymer.
• JP-B No. 55-9435 suggests, for example, a resin composition composed of a polycarbonate resin, polyester resin and butadiene-based graft copolymer.
• a resin composition manifests an effect of improving impact resistance only when the formulation of a polycarbonate resin, polyester resin and butadiene-based graft copolymer is restricted in a relatively narrow range, and has poor molded article appearance which causes decrease in glossiness, being able to be improved.
• JP-B No. 62-26343, JP-B No. 62-46578 and JP-B No. 7-5825 suggest resin compositions composed of a polycarbonate resin, polyester resin and butadiene-based graft copolymer, however, an effect of imparting impact resistance and molded appearance can not be necessarily satisfied simultaneously in these compositions.
• the present invention has been accomplished in view of such current conditions and an object thereof is to provide a thermoplastic resin composition excellent in impact resistance and molded appearance.
• thermoplastic resin composition comprising
• the present invention provides a thermoplastic resin composition excellent in impact resistance and molded appearance, by adopting the constitution as described above.
• a polycarbonate resin, the component (A) in the present invention can be an aromatic polycarbonate resin, and can be a polycarbonate produced using a dihydroxydiphenyl alkane as the main raw material.
• polycarbonates obtained by a transesterification method or phosgene method using 2,2-(4,4'-dihydroxydiphenyl)propane (bisphenol A) as a dihydroxy component are preferable.
• bisphenol A 2,2-(4,4'-dihydroxydiphenyl)propane
• part or all of the above-mentioned bisphenol A may be substituted with other 4,4'-dihydroxydiphenyl alkane or 4,4'-dihydroxydiphenylsulfone, 4,4'-dihydroxydiphenyl ether and the like, and two or more of them may also be mixed and used.
• the content of the component (A) polycarbonate resin is from 4 to 95% by weight based on 100% by weight of the whole amount of a thermoplastic resin composition of the present invention. By such a content range, a resin composition excellent in impact resistance and molded appearance is obtained.
• a saturated polyester resin, the component (B) used in the present invention is a resin obtained by a condensation reaction using an aromatic dicarboxylic acid or ester-forming derivative thereof and alkylene glycol as the main components.
• aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid and the like.
• alkylene glycol include ethylene glycol, propylene glycol, tetramethylene glycol, hexamethylene glycol and the like. In addition to them, other dicarboxylic acids and glycols may also be copolymerized in small amount, if necessary.
• the preferable saturated polyester resin include polytetramethylene terephthalate, polyethylene terephthalate and a mixture thereof.
• a polyester-based elastomer, the component (B) in the present invention is a block copolymer having a polyester segment having high melting point and a polymer segment having low melting point.
• the polyester segment having high melting point is a polyester obtained by a condensation reaction of an aromatic dicarboxylic acid with an alkylene glycol.
• aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid and the like.
• alkylene glycol include ethylene glycol, propylene glycol, tetramethylene glycol, hexamethylene glycol and the like. In addition to them, other dicarboxylic acids and glycols may also be copolymerized in small amount, if necessary.
• the preferable polyester include polytetramethylene terephthalate, polyethylene terephthalate and a mixture thereof.
• the polymer segment having low melting point is composed of a polymer having a molecular weight from 400 to 20000 such as a polyalkylene ether glycol, aliphatic polyester and the like.
• a polyalkylene ether glycol such as poly(ethylene oxide) glycol, poly(tetramethylene oxide) glycol, poly(propylene oxide) glycol and a mixture thereof.
• the aliphatic polyester include polyesters obtained from an aliphatic dicarboxylic acid having 2 to 12 carbon atoms and an aliphatic glycol having 2 to 10 carbon atoms.
• Examples of the preferable polymer segment having low melting point include polyethylene adipate, polytetramethylene adipate, polyethylene sebacate, polyneopentyl sebacate, polyhexamethylene azelate, poly- ⁇ -caprolactone and the like.
• the proportion of these polymer segments having low melting point in the polyester-based elastomer is preferably from 2 to 80% by weight.
• the total content of the component (B) saturated polyester resin and/or polyester-based elastomer is from 4 to 95% by weight based on 100% by weight of the whole amount of the resin composition. By such a content range, a resin composition excellent in impact resistance and molded appearance is obtained.
• a graft copolymer, the component (C) in the present invention is a graft copolymer obtained by graft-polymerizing a monomer or monomer mixture containing at least an aromatic vinyl, alkyl methacrylate or alkyl acrylate in the presence of latex containing a butadiene-based rubber polymer, and this copolymer is obtained under the following conditions (a) to (c).
• the latex containing a butadiene-based rubber polymer is composed of a monomer composition containing 50 to 100% by weight of 1,3-butadiene and 0 to 50% by weight of one or more vinyl-based monomers copolymerized with 1,3-butadiene.
• vinyl-based monomer examples include aromatic vinyls such as ⁇ -methylstyrene and the like, alkyl methacrylates such as methyl methacrylate, ethyl methacrylate and the like, alkyl acrylates such as ethyl acrylate, n-butyl acrylate and the like, unsaturated nitriles such as acrylonitrile, methacrylonitrile and the like, vinyl ethers such as methyl vinyl ether, butyl vinyl ether and the like, halogenated vinyls such as vinyl chloride, vinyl bromide and the like, halogenated vinylidenes such as vinylidene chloride, vinylidene bromide and he like, vinyl-based monomers having a glycidyl group such as glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, ethylene glycol glycidyl ether and the like.
• aromatic vinyls such as
• cross-linking monomers such as aromatic polyfunctional vinyl compounds such as divinylbenzene, divinyltoluene and the like, polyhydric alcohols ethylene glycol dimethacrylate, 1,3-butanediol diacrylate and the like, trimethacrylates, triacrylates, allyl carboxylates such as allyl acrylate, allyl methacryalte and the like, di and tri-allyl compounds such as diallyl phthalate, diallyl sebacate, triallyltriazine and the like.
• aromatic polyfunctional vinyl compounds such as divinylbenzene, divinyltoluene and the like
• polyhydric alcohols ethylene glycol dimethacrylate, 1,3-butanediol diacrylate and the like
• trimethacrylates trimethacrylates
• triacrylates allyl carboxylates
• allyl acrylate allyl methacryalte and the like
• di and tri-allyl compounds
• the above-mentioned vinyl-based monomers and cross-linking monomers can be used alone or in combination of two or more.
• chain transfer agents such as t-dodecylmercaptane, n-octylmercaptane, ⁇ -methylstyrene and the like can be used, if necessary.
• an emulsion polymerization method is used, and the polymerization can be appropriately used at temperatures in the range from 40 to 80°C depending on the kind of a polymerization initiator.
• the emulsifier known emulsifiers can appropriately be used.
• seed latex composed of styrene and the like may previously be charged, for example.
• the polymerization method a multi-stage emulsification polymerization is preferable.
• the monomer formulation charged initially and the monomer formulation charged subsequently may be the same or different.
• the weight-average particle size (d w ) is from 100 to 200 nm, preferably from 130 to 180 nm, and the ratio (d w /d n ) of the weight-average particle size (d w ) to the number-average particle size (d n ) is from 1 or more and 3 or less, preferably 1 or more and 2 or less.
• the average particle size and particle size distribution are specified as described above, and by this, desired structural control can be suitably effected in obtaining the component (C), and a resin composition having high quality can be obtained stably. Specifically, a resin composition having effectively improved impact resistance can be obtained while maintaining the appearance and glossiness of a molded article.
• a graft copolymer, the component (C) in the present invention is obtained by adding a monomer or monomer mixture containing at least an aromatic vinyl, alkyl methacrylate or alkyl acrylate, further adding, if necessary, a vinyl-based monomer copolymerized therewith, and grafting them, in the presence of butadiene-based rubber polymer latex having the above-mentioned constitution.
• the monomer used in the graft polymerization there can be used aromatic vinyls such as styrene, ⁇ -methylstyrene and various halogen-substituted and alkyl-substituted styrenes, alkyl methacrylates such as methyl methacrylate, ethyl methacryalte and the like, alkyl acrylates such as ethyl acrylate, n-butyl acrylate and the like, unsaturated nitriles such as acrylonitrile, methacrylonitrile and the like, vinyl-based monomers having a glycidyl group such as glycidyl acrylate, glycidyl methacryalte, allyl glycidyl ether, ethylene glycol glycidyl ether and the like, and monomer mixtures with the above-mentioned cross-linking monomer.
• aromatic vinyls such as styren
• the amount of a monomer or monomer mixture used in the graft polymerization is from 10 to 40% by weight based on 60 to 90% by weight of a butadiene-based rubber polymer.
• the amount of a monomer or monomer mixture used in the graft polymerization is too large, an effect of improving impact resistance decreases, and when too small, the dispersion of a graft copolymer (C) in a resin composition is insufficient, and the appearance of a molded article is poor, and glossiness deteriorates.
• a persulfate salt such as potassium persulfate, ammonium persulfate, sodium persulfate and the like, an organic peroxide such as t-butyl hydroperoxide, cumene hydroperoxide, benzoyl peroxide, lauroyl peroxide, diisopropylbenzene hydroperoxide and the like, an azo compound such as azobisisobutyronitrile, azobisisovaleronitrile and the like, or a redox initiator obtained by combining the above-mentioned compound with a sulfite salt, hydrogen sulfite salt, thiosulfate salt, metal (I) salt, sodiumformaldehyde sulfoxylate, dextrose and the like, if necessary.
• a persulfate salt such as potassium persulfate, ammonium persulfate, sodium persulfate and the like, an organic peroxide such as t-buty
• the graft polymerization method an emulsion polymerization method is used.
• the polymerization can be appropriately effected at temperatures in the range from 40 to 80 °C depending on the kind of the polymerization initiator.
• the emulsifier known emulsifiers can appropriately be used.
• the polymerization is preferably conducted according to a multi-stage graft polymerization method. Namely, it is preferable that latex is previously charged in the reaction system and monomers to be grafted are added separately, or added continuously. By adopting such a polymerization method, a graft copolymer having a desired structure can be obtained relatively easily.
• a multi-stage graft polymerization method in which an alkyl methacryalte and alkyl acrylate are polymerized in the first stage, an aromatic vinyl is polymerized in the second stage and an alkyl methacrylate is polymerized in the third stage, or a multi-stage graft polymerization method in which an alkyl methacryalte is polymerized in the first stage, an aromatic vinyl is polymerized in the second stage and an alkyl methacrylate is polymerized in the third stage is desirably adopted.
• a graft copolymer having a desired structure can be obtained more easily, and further, production stability and quality stability are also excellent.
• the resulted graft copolymer latex is heat-treated to be solidified, appropriately using a coagulant such as an acid like sulfuric acid, hydrochloric acid, phosphoric acid and the like or a salt like calcium chloride, sodium chloride and the like, with or without adding a suitable antioxidant or additive, then, dehydrated and washed, subsequently, dried or spray-dried to give a graft copolymer (C) in the form of a powder.
• a coagulant such as an acid like sulfuric acid, hydrochloric acid, phosphoric acid and the like or a salt like calcium chloride, sodium chloride and the like
• the content of the component (C) graft copolymer is from 1 to 40% by weight based on 100% by weight of the whole amount of a resin composition. By adopting such a content range, a resin composition excellent in impact resistance and molded appearance is obtained.
• thermoplastic resin composition of the present invention As the use of a thermoplastic resin composition of the present invention, automatic parts and the like are listed. In the case of automatic parts use, particularly excellent appearance is necessary, and the glossiness is desirably 80% or more.
• thermoplastic resin composition can be produced by various methods such as a method in which powders or granules are mixed by a known technology, for example, a Henschel mixer, tumbler and the like, the mixture is melt-mixed by an extruder, kneader, mixer and the like, a method in which into previously melted components, other components are mixed sequentially, further a method in which a mixture is molded directly by an injection molding machine, and the like.
• thermoplastic resin composition of the present invention stabilizers against heat or light, for example, phenol-based stabilizers, phosphite-based stabilizers, ultraviolet absorbers, amine-based stabilizers may be added.
• anti-hydrolysis modifiers for example, epoxy-based modifiers may also be added.
• known frame retardants and fillers such as titanium oxide, talk and the like, dyes and pigments, plasticizers and the like can be added, if necessary.
• composition as a first monomer was charged into a 70 L autoclave, heated and a redox-based initiator was added into the autoclave when the temperature reached 43°C to initiate the reaction, then, the mixture was further heated up to 65°C.
• 1,3-butadiene 25.5 parts styrene 4.5 parts p-methane hydroperoxide 0.1 parts sodium pyrophosphate 0.5 parts potassium oleate 0.2 parts de-ionized water 70 parts
• ferrous sulfate 0.003 parts dextrose 0.3 parts de-ionized water 5 parts
• the initiator was added into the autoclave, and from directly after the addition, a second monomer, de-ionized water and emulsifier were continuously added over 2 hours.
• the mixture was reacted for 10 hours after the initiation of the polymerization, to obtain butadiene-based rubber polymer latex (r-1).
• the resulted butadiene-based rubber polymer latex (r-1) had a particle size d w of 160 nm and d w /d n of 1.5.
• composition as a monomer was charged into a 70 L autoclave, heated and a redox-based initiator was added into the autoclave when the temperature reached 43°C to initiate the reaction, then, the mixture was further heated. up to 65°C.
• 1,3-butadiene 85 parts styrene 15 parts p-methane hydroperoxide 0.3 parts sodium pyrophosphate 0.5 parts potassium oleate 1.0 part de-ionized water 145 parts
• ferrous sulfate 0.003 parts dextrose 0.3 parts de-ionized water 5 parts
• the resulted butadiene-based rubber polymer latex (r-2) had a particle size d w of 90 nm and d w /d n of 1.3.
• graft copolymer (C-1) 0.5 parts of butylated hydroxytoluene was added to the resulted graft copolymer latex, then, a 0.2% aqueous sulfuric acid solution was added to produce a coagulated material which was heat-treated at 90°C to be solidified. Thereafter, the coagulated material was washed with hot water, and further dried to give a graft copolymer (C-1).
• graft copolymer (S-1) 0.5 parts of butylated hydroxytoluene was added to the resulted graft copolymer latex, then, a 0.2% aqueous sulfuric acid solution was added to produce a coagulated material which was heat-treated at 90°C to be solidified. Thereafter, the coagulated material was washed with hot water, and further dried to give a graft copolymer (S-1).
• graft copolymer (S-2) 0.5 parts of butylated hydroxytoluene was added to the resulted graft copolymer latex, then, a 0.2% aqueous sulfuric acid solution was added to produce a coagulated material which was heat-treated at 90°C to be solidified. Thereafter, the coagulated material was washed with hot water, and further dried to give a graft copolymer (S-2).
• a graft copolymer (C-2) was obtained in the same manner as in (b-3) except that the butadiene-based rubber polymer latex (r-2) obtained in the above-mentioned polymerization (a-2) was used.
• a graft copolymer (C-3) was obtained in the same manner as in (b-3) except that 75 parts of the butadiene-based rubber polymer latex (r-2) obtained in the above-mentioned polymerization (a-2) as a solid component, 1.5 parts of potassium oleate, 0.6 parts of sodiumformaldehyde sulfoxylate and 0.9 parts of sodium chloride were used. When thickened with sodium chloride, the rubber particle had a particle size d w of 160 nm and d w /d n of 9.7.
• Thermoplastic resin compositions of the examples of the present invention had excellent molded appearance (glossiness), and excellent impact resistance imparting effect was recognized.
• Thermoplastic resin compositions of the examples of the present invention had changed compounding ratios of the polycarbonate and polyester as compared with Examples 1 to 2 and Examples 5 to 6, however, also in the present cases, had excellent molded appearance (glossiness), and excellent impact resistance imparting effect was manifested.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Graft Or Block Polymers (AREA)

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• 1999
  • 1999-07-16 JP JP2000560195A patent/JP4580553B2/ja not_active Expired - Lifetime
  • 1999-07-16 CN CNB998098310A patent/CN1148413C/zh not_active Expired - Fee Related
  • 1999-07-16 ES ES99929862T patent/ES2214862T3/es not_active Expired - Lifetime
  • 1999-07-16 US US09/743,786 patent/US6407167B1/en not_active Expired - Lifetime
  • 1999-07-16 WO PCT/JP1999/003833 patent/WO2000004094A1/fr not_active Ceased
  • 1999-07-16 AT AT99929862T patent/ATE261472T1/de not_active IP Right Cessation
  • 1999-07-16 DE DE69915495T patent/DE69915495T2/de not_active Revoked
  • 1999-07-16 KR KR1020017000700A patent/KR100645794B1/ko not_active Expired - Lifetime
  • 1999-07-16 EP EP99929862A patent/EP1111008B1/fr not_active Revoked

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